Electric field assisted placement of nanomaterials through dielectric engineering

ABSTRACT

A method of positioning nanomaterials includes patterning guiding dielectric features from a single layer of guiding dielectric material, and producing an electric field by at least one electrode disposed on a substrate that is attenuated through the guiding dielectric features to create an attractive dielectrophoretic force that guides at least one nanostructure abutting the guiding dielectric features to be positioned on a deposition surface of the substrate.

BACKGROUND Technical Field

The present invention generally relates to nanomaterials, and moreparticularly to methods of controlling the orientation of nanomaterials.

Description of the Related Art

Nanomaterials have been successfully used as functional building blocksto fabricate multi-dimensional (D) ordered assemblies with potentialapplications in nanoelectronic and optic devices. Examples ofnanomaterials include nanowires, nanotubes, nanoparticles, nanocrystalsand nanosheets. Orientating nanomaterials in efforts to form structures,such as those used in nanoelectronic and optical devices, can includesolution based methods. Some examples of placement methods rely onsubstrate patterning, chemical surface functionalization,Langmuir-Blodgett type techniques, or a combination thereof. The controlof the nanomaterial position, orientation and density is substantiallylimited using the aforementioned methods.

SUMMARY

In accordance with an embodiment, a method of positioning nanomaterialsis provided using electronic field and a guiding dielectric layer. Inone embodiment, the method of positioning the nanomaterials includesforming guiding dielectric structures from a single material layer on asubstrate including at least one electrode, wherein an exposed portionof the substrate between the dielectric guide features provides adeposition surface. The method further includes producing an electricfield by the electrodes to create an attractive force that guides atleast one nanostructure to the deposition surface but is attenuatedthrough the dielectric guide features.

In another embodiment, the method includes forming a set of electrodeson a substrate; and covering the electrodes and substrate with a singlelayer of guiding dielectric material. The guiding material is thenpatterned to provide dielectric guide features, wherein an exposedportion of the substrate between the dielectric guide features providesa deposition surface. The guiding dielectric features and the depositionsurface are submerged in a liquid medium containing at least onenanostructure. An electric field produced by the electrodes that isattenuated by the dielectric guide features creates an attractive forcethat, guides the nanostructures to the deposition surface.

In yet another embodiment, the method of positioning nanomaterials mayinclude forming a set of electrodes on a substrate; and covering theelectrodes and the substrate with a single layer of guiding dielectricmaterial. The single layer of guiding dielectric material is patternedto pro dielectric guide features, wherein an exposed portion of thesubstrate between the dielectric guide features provides a depositionsurface. An electric field produced by the electrodes that is attenuatedby the dielectric guide features creates an attractive force that guidesat least one nanostructure to the deposition surface.

In yet another embodiment, a method of positioning nanomaterials isprovided. The method includes patterning guiding dielectric featuresfrom a single layer of guiding dielectric material, and producing anelectric field by at least one electrode disposed on a substrate that isattenuated through the guiding dielectric features to create anattractive dielectrophoretic force that guides at least onenanostructure abutting the guiding dielectric features to be positionedon a deposition surface of the substrate.

In yet another embodiment, a method of positioning nanomaterials isprovided. The method includes forming a set of electrodes on asubstrate, covering the set of electrodes and the substrate with asingle layer of guiding dielectric material, patterning the single layerof guiding dielectric material to form dielectric guide features,applying a liquid medium containing at least one nanostructure to theguiding dielectric features and the deposition surface, and producing anelectric field by the set of electrodes that is attenuated by thedielectric guide features to create a dielectrophoretic attractive forcethat guides the at least one nanostructure to a deposition surface ofthe substrate without positioning the at least one nanostructure atopthe dielectric; guide features.

In yet another embodiment, a method of positioning nanomaterials isprovided. The method includes covering a substrate and a set ofelectrodes formed on the substrate with a single layer of guidingdielectric material, patterning the single layer of guiding dielectricmaterial to form dielectric guide features, and producing an electricfield by the set of electrodes that is attenuated by the dielectricguide features to create an attractive force that guides at least onenanostructure to a deposition surface of the substrate withoutpositioning the at least one nanostructure atop the dielectric guidefeatures.

These and other features and advantages will become apparent from thefollowing detailed description of illustrative embodiments thereof,which is to be read in connection with the accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

The following description will provide details of preferred embodimentswith reference to the following figures wherein:

FIG. 1A is a plot of the attractive (DEP) force as a function of thedistance to the substrate from samples including a dielectric layeroverlying an electrode, and a comparative sample that does not includethe dielectric layer, in accordance with one embodiment of the presentdisclosure.

FIG. 1B is a side cross-sectional view of an experimental sampleincluding a dielectric layer overlying an electrode, which provided atleast one data point depicted in FIG. 1A.

FIG. 1C is a side cross-sectional view of a comparative sample that doesnot include the dielectric layer, which provided at least one data pointdepicted in FIG. 1A.

FIG. 2A is a top down view depicting forming a first mask on asubstrate, wherein the mask is patterned to provide the geometry ofelectrodes, in accordance with an embodiment of the present invention.

FIG. 2B is a side cross-sectional view along section line B-B of FIG.2A.

FIG. 3 is a side cross-sectional view illustrating one embodiment offorming an electrically conductive material that is present within theopenings that are present in the first masking.

FIG. 4A is a top down view illustrating one embodiment of a lift offmethod for removing the masking depicted in FIG. 3, in accordance withthe present disclosure.

FIG. 4B is a side cross-sectional view along section line B-B of FIG.4A.

FIG. 5 is a side cross-sectional view depicting forming a singledielectric layer over the electrodes depicted in FIGS. 4A and 4B.

FIG. 6A is a top down view illustrating forming a second mask on thesingle dielectric layer that is depicted in FIG. 5, in accordance withone embodiment of the present disclosure.

FIG. 6B is a side cross-sectional view along section line B-B of thestructure depicted in 6A.

FIG. 7 is a top down view depicting etching the single dielectric layerusing the second mask as an etch mask to provide dielectric guidingfeatures that in combination with an electric field provide anattractive force that can orientate nanostructures, in accordance withone embodiment of the present disclosure.

FIG. 8A is a top down view depicting the structure illustrated in FIG. 7after removing the second mask to expose the dielectric guidingfeatures, in accordance with one embodiment of the present disclosure.

FIG. 8B is a side cross-sectional view along section line B-B of thestructure depicted in FIG. 8A.

FIG. 8C is a top down view depicting another embodiment of dielectricguiding features that can be formed in accordance with the methods ofthe present disclosure,

FIG. 8D is a top down view depicting yet another embodiment of thedielectric guiding features that can be formed in accordance with themethods of the present disclosure.

FIG. 9A is a top down view depicting the orientation of nanostructureson the deposition surface of a substrate, wherein an electric fieldproduced by the electrodes that is attenuated by the dielectric guidefeatures creates an attractive force that guides the nanostructures tothe deposition surface, in accordance with one embodiment of the presentdisclosure.

FIG. 9B is a side cross-sectional view along section line B-B of thestructure depicted in FIG. 9A,

FIG. 10A is a top down view depicting removing the dielectric guidefeatures from the structure depicted in FIGS. 9A and 9B, in accordancewith one embodiment of the present disclosure.

FIG. 10B is a side cross-sectional view along section line B-B of thestructure depicted in FIG. 10A.

DETAILED DESCRIPTION

Detailed embodiments of the claimed structures and methods are disclosedherein; however, it, is to be understood that, the disclosed embodimentsare merely illustrative of the claimed structures and methods that maybe embodied in various forms. In addition, each of the examples given inconnection with the various embodiments is intended to be illustrative,and not restrictive. Further, the figures are not necessarily to scale,some features may be exaggerated to show details of particularcomponents. Therefore, specific structural and functional detailsdisclosed herein are not to be interpreted as limiting, but merely as arepresentative basis for teaching one skilled in the art to variouslyemploy the methods and structures of the present disclosure. Forpurposes of the description hereinafter, the terms “upper”, “lower”,“right”, “left”, “vertical”, “horizontal”, “top”, “bottom”, andderivatives thereof shall relate to the embodiments of the disclosure,as it is oriented in the drawing figures. The terms “positioned on”means that a first element, such as a first structure, is present on asecond element, such as a second structure, wherein interveningelements, such as an interface structure, e.g. interface layer, may bepresent between the first element and the second element. The term“direct contact” means that a first element, such as a first structure,and a second element, such as a second structure, are connected withoutany intermediary conducting, insulating or semiconductor layers at theinterface of the two elements.

In some embodiments, the methods and structures disclosed herein providefor an electric field assisted placement of nanomaterials throughdielectric engineering. The methods and structures described hereinprovide for the solution based, aligned placement of nanomaterials,nanowires, nanotubes, nanocrystals, nanosheets and combinations thereof,on an insulating (also referred to as dielectric) substrate. Priormethods for nanomaterial placement, such as those that rely on substratepatterning, chemical surface functionalization, Langmuir-Blodgett-typetechniques or other related techniques, are limited in their control ofnanomaterial position, orientation and density.

It has further been determined that electric field driven assemblymethods, or dielectrophoresis, require precise patterning of metallicelectrodes for the application of an electric field at the locationwhere the nanomaterial assembly should occur. The methods and structuresdisclosed herein overcome the aforementioned limitations by employing asimple, metallic contact layout combined with a single dielectric layerdesigned to achieve assembly of the nanomateriais with nanometerprecision. As will be described in further detail below, in someembodiments, the methods and structures described herein combinestandard semiconductor processing steps, i.e., lithography, dielectricand metal thin film deposition processing steps; and an etch processstep, in order to place nanometer scale material with nanometerprecision based on electric field assisted assembly.

FIGS. 1A-1C outline the basic working principle of the methods andstructures that are described herein for providing electric fieldassisted placement of nanomaterials through dielectric engineering. Ithas been determined that attractive dielectrophoretic (DEP) forcesgenerated by metallic leads decrease, i.e., fall off, exponentiallyabove a dielectric substrate surface. DEP is a phenomenon in which aforce is exerted on a dielectric particle when it is subjected to anon-uniform electric field. This force does not require the particle tobe charged. Typically, the strength of the force depends on the mediumand particles' electrical properties, on the particles' shape and size,as well as on the frequency of the electric field. Consequently, fieldsof a particular frequency can manipulate particles with selectivity.Therefore, the resulting force exerted on a nanostructure is uniquelydetermined by design of the dielectric layer. This is illustrated inFIGS. 1A-1C.

FIG. 1A is a plot of the attractive DEP force as a function of thedistance to the substrate from samples including a dielectric materiallayer overlying an electrode, as depicted in FIG. 1B, and a comparativesample that does not include the dielectric material layer, as depictedin FIG. 1C. Referring to FIG. 1B, the dielectric material layer, e.g.,aluminum oxide material layer, identified by reference number 4 ispresent over an electrode identified by reference number 5. Theelectrode is composed of an electrically conductive material, such ascopper (Cu) or aluminum (Al). The electrode identified by referencenumber 5 is present on a substrate that is identified by referencenumber 6. The substrate may be a semiconductor substrate, such as asilicon (Si) substrate. Referring to FIG. IC, the comparative sample issimilar to the sample depicted in FIG. 1B, and includes a similarelectrode 5 and substrate 6, but does not include the dielectric layer4. Both the comparative sample depicted in FIG. 1C and the sampledepicted in FIG. 1B are submerged in a toluene based solvent.Measurements of the attractive (DEP) force where taken from the toptopography corner 7 of the dielectric material layer 4 of the sampledepicted in FIG. 1B. Measurements of the attractive (DEP) force wheretaken from the top corner 8 of the electrode 5 of the comparative sampledepicted in FIG. 1C.

Referring to FIG. 1A, the data line for the attractive (DEP) forceprovided by the sample including the dielectric material layer overlyingthe electrode is identified by reference number 3, and the data line forthe attractive (DEP) force provided by the comparative sample that doesnot include the dielectric material layer is identified by referencenumber 2. From the data plotted in FIG. 1A, for realistic dielectriclayer thicknesses, e.g., 5 nm to 100 nm, the force difference exerted onnanostructures at the same lateral and vertical position with andwithout dielectric layer can be on the order of 1:100. Therefore,nanomaterials only “feel” an attractive force in regions withoutdielectric layer, e.g., aluminum oxide material layer as illustrated inthe comparison of FIGS. 1B and 1C with the data plotted in FIG. 1A. Ithas been determined that in some embodiments the placement ofnanostructures can be precisely tailored by proper design of a singledielectric layer. The methods and structures of the present disclosureare now described with greater detail referring to FIGS. 2-10B.

FIGS. 2A and 2B depict one embodiment of a patterning method as part ofa process for forming contact leads. In some embodiments, the method mayinclude forming a mask 15 atop a substrate 10. The substrate 10 may becomposed of a semiconductor or dielectric material. For example, thesubstrate 10 may be composed of a type IV or type III-V semiconductor.For example, the substrate 10 may be composed of a type IVsemiconductor, such as silicon, silicon germanium and/or germanium. Thesubstrate 10 may also be composed of a type semiconductor material. Insome examples, described herein, the supporting substrate is composed ofsilicon (Si). Although the substrate 10 is depicted as being a bulksubstrate, in some other examples, the substrate 10 may also be providedby a semiconductor, e.g., silicon, on insulator (SOI) substrate. In someembodiments, when the substrate 10 is composed of a dielectric material,the substrate 10 may be composed of glass, silicon oxide, aluminum oxideand combinations thereof. In some embodiments, the substrate 10 iscomposed of a polymer type material. In some examples, the substrate 10is composed of glass, quartz, silicon carbide, silicon nitride (Si₃N₄)and combinations thereof.

Forming the first mask 15 on the substrate 10 may include deposition,photolithography, and development process steps. First, a photoresistmaterial layer is blanket deposited atop an entire upper surface of thesubstrate 10. Thereafter, the photoresist material layer is patterned toprovide the first mask 15. Specifically, a pattern is produced byapplying a photoresist to the surface to be etched; exposing thephotoresist to a pattern of radiation; and then developing the patterninto the photoresist utilizing conventional resist developer, wherein aportion f the photoresist layer may dissolve and a portion of thephotoresist mask remains to provide the first mask 15. It is noted thatthis is only one example for forming a first mask 15, and other methodsof forming a first mask 15 are equally applicable to the presentdisclosure. For example, the mask can be a soft mask, like optical orelectron-beam lithography resist (e.g., poly(methyl methacrylate)(PMMA), hydrogen silsesquioxane (HSQ), or S1818™ available from DOW®. Inanother example, a hard mask, like an oxide, nitride, or metal depositedby a compatible deposition method. The first masking 15 is patterned toprovide the geometry of electrically conductive features 20. Morespecifically, the openings 16 in the mask 14 may provide the geometry ofthe electrically conductive features 20. The electrically conductivefeatures 20 may be formed in accordance with lift off methods, asdescribed below. The electrically conductive features 20 may provideelectrodes that are present on an upper surface of a substrate 10.

FIG. 3 illustrates one embodiment of forming an electrically conductivematerial 20 that is present at least within the openings that, arepresent in the masking 15. The term “electrically conductive” as usedthrough the present disclosure means a material typically having a roomtemperature conductivity of greater than 10⁻⁸(−m)⁻¹. Examples ofelectrically conductive materials for the electrically conductivematerial 20 include metals, metal nitrides, metal semiconductor alloys,e.g., silicides, and doped semiconductor, e.g., n-type dopedpolysilicon. Examples of metals for the electrically conductive material20 include copper (Cu), aluminum (Al), titanium (Ti), tungsten (W),tantalum (Ta), silver (Ag), gold (Au) and combinations thereof.

The electrically conductive material 20 may be deposited on the masking15 and within the openings 16 in the masking 15 using a depositionprocess, such as physical vapor deposition (PVD), chemical vapordeposition (CND), atomic layer deposition (ALD) or plating. The PVDmethod for forming the electrically conductive material 20 may includesublimation, evaporation, sputtering and combinations thereof. Examplesof sputtering apparatus that may be suitable for depositing electricallyconductive material 20 include DC diode type systems, radio frequency(RF) sputtering, magnetron sputtering, and ionized metal plasma (IMP)sputtering. The CVD method for forming the electrically conducivematerial 20 include, but are not limited to, atmospheric pressure(APCVD), low pressure (LPCVD), plasma enhanced (PECVD), metal organic(MOCVD), and combinations thereof. The plating methods for forming theelectrically conductive material 20 may include electroplating orelectroless plating.

FIGS. 4A and 4B illustrate one embodiment of a lift off method forremoving the masking 15. By removing the mask 15, the portion of theelectrically conductive material 20 that is present on the upper surfaceof the mask 15, i.e., not present in the openings 16 in the mask, isalso removed. The portion of the electrically conductive material 15that was formed in the openings 16 in the mask 15 directly on thesubstrate 10 remains after the lift off process to provide electrodes.

FIG. 5 depicts one embodiment of forming a single dielectric layer 25over the electrodes 20 depicted in FIGS. 4A and 4B. The singledielectric layer 25 may be composed of any dielectric material, such asan oxide, nitride or oxynitride material layer. For example, thedielectric material for the single dielectric layer 25 may be siliconoxide (SiO₂), aluminum oxide (Al₂O₃) and hafnium oxide (HfO₂). It isnoted that the above examples are provided for illustrative purposesonly. For example, the dielectric material for the single dielectriclayer 25 may be organosilicate glass (OSG), fluorine doped silicondioxide, carbon doped silicon dioxide, porous silicon dioxide, porouscarbon doped silicon dioxide, spin-on organic polymeric dielectrics(e.g., SILK™), spin-on silicone based polymeric dielectric (e.g.,hydrogen silsesquioxane (HSQ) and methylsilsesquioxane (MSQ)), andcombinations thereof. In another example, the single dielectric layer 25may be hafnium oxide, hafnium silicon oxide, hafnium silicon oxynitride,lanthanum oxide, lanthanum aluminum oxide, zirconium oxide, zirconiumsilicon oxide, zirconium silicon oxynitride, tantalum oxide, titaniumoxide, barium strontium titanium oxide, barium titanium oxide, strontiumtitanium oxide, yttrium oxide, aluminum oxide, lead scandium tantalumoxide, lead zinc niobate and combinations thereof. In yet anotherexample, the single dielectric layer 25 may be selected from the groupconsisting of zirconium oxide (ZrO₂), aluminum oxide (Al₂O₃), hafniumsilicate (HfSiO), nitrided hafnium silicate (HfSiON), hafnium oxynitride(HfO_(x)N_(y)), lanthanum oxide (La₃O₂), lanthanum aluminate (LaAlO₃),zirconium silicate (ZrSiO_(x)) and combinations thereof.

The single dielectric layer 25 may be deposited using atomic layerdeposition (ALD), chemical vapor deposition (CVD), thermal evaporationor a combination thereof. In some embodiments, the single dielectriclayer 25 may be deposited using a chemical vapor deposition (CVD)process selected from atmospheric pressure (APCVD), low pressure(LPCVD), plasma enhanced (PECVD), metal organic (MOCVD), andcombinations thereof. The single dielectric layer 25 may be deposited toa thickness ranging from 5 nm to 100 nm. In another embodiment, thesingle dielectric layer 25 may be deposited to a thickness ranging from10 nm to 50 nm.

In some embodiments, after depositing the single dielectric layer 25 theupper surface of the deposited material layer may be planarized toprovide a planar upper surface. For example, the upper surface of thesingle dielectric layer 25 may be planarized using grinding or chemicalmechanical planarization (CMP).

The term “single” as used to describe the single dielectric layer 25denotes that only one material layer is used to provide the guidingdielectric features 25′. The single dielectric layer 25 typically has asingle composition.

FIGS. 6A and 6B depict one embodiment of forming a second mask 29. Thesecond mask 29 is patterned to provide an etch mask for etching thesingle dielectric layer 25 to provide guiding dielectric features 25′.In some examples, the second mask 29 may be patterned byoptical/electron beam lithography or direct laser writing.

In one example, forming the second mask 29 on the single dielectriclayer 25 may include deposition, photolithography, and developmentprocess steps. First, a photoresist material layer is blanket depositedatop an entire upper surface of the single dielectric layer 25.Thereafter, the photoresist material layer is patterned to provide thesecond mask 29. Specifically, a pattern is produced by applying aphotoresist to the surface to be etched; exposing the photoresist to apattern of radiation; and then developing the pattern into thephotoresist utilizing conventional resist developer, wherein a portionof the photoresist layer may dissolve and a portion of the photoresistmask remains to provide the second mask 29. It is noted that this isonly one example for forming a second mask 29, and other methods offorming a second mask 29 are equally applicable to the presentdisclosure. For example, the mask can be a soft mask, like optical orelectron-beam lithography resist (e.g., poly(methyl methacrylate)(PMMA), hydrogen silsesquioxane (HSQ), or S1818™ available from DOW®. Inanother example, a hard mask, like an oxide, nitride, or metal depositedby a compatible deposition method. The second mask 29 is patterned toprovide the geometry of the guiding dielectric features 25′. Morespecifically, the openings in the second mask 29 expose the portions ofthe single dielectric layer 25 that are removed to expose the underlyingsubstrate 10, which provide the deposition surface for the laterorientated nanostructures. The guiding dielectric features 25′ are usedin combination with an electric field produced by the electricallyconducive features 20, e.g., electrodes, to provide an attractive forcethat, orientates nanostructures to the deposition surfaces on thesubstrate 10 between the guiding features 25′.

FIG. 7 depicts etching the single dielectric layer 25 using the secondmask 29 as an etch mask to provide dielectric guiding features 25′ thatin combination with an electronic field provide an attractive force thatcan orientate nanostructures 30. The etch process for etching the singledielectric layer 25 may be an anisotropic etch process. As used herein,an “anisotropic etch process” denotes a material removal process inwhich the etch rate in the direction normal to the surface to be etchedis greater than in the direction parallel to the surface to be etched.The anisotropic etch way include reactive ion etching (RIE). ReactiveIon Etching (RIE) is a form of plasma etching in which during etchingthe surface to be etched is placed on the RF powered electrode.Moreover, during RIE the surface to be etched takes on a potential thataccelerates the etching species extracted from plasma toward thesurface, in which the chemical etching reaction is taking place in thedirection normal to the surface. Other examples of anisotropic etchingthat can be used at this point of the present invention include ion beametching, plasma etching or laser ablation.

In one embodiments, the etch process for etching the single dielectriclayer 25 may remove the dielectric material of the single dielectriclayer 25 selectively to the second mask 29, the substrate 10 and theelectrodes 20. As used herein, the term “selective” in reference to amaterial removal process denotes that the rate of material removal for afirst material is greater than the rate of removal for at least anothermaterial of the structure to which the material removal process is beingapplied. For example, in one embodiment, a selective etch may include anetch chemistry that removes a first material selectively to a secondmaterial by a ratio of 100:1 or greater.

In some other examples, the single dielectric layer 25 may be etchedusing argon sputtering.

FIGS. 8A-8D depicting the structure illustrated in FIG. 7 after removingthe second mask 29 to expose the dielectric guiding features 25′. Thesecond mask 29 may be removed by a selective etch process, or by achemical strip process.

FIG. 8A depicts one embodiment of the dielectric guiding features 25′that can be formed in accordance with this method. The space betweenadjacent dielectric guiding features 25′ exposes a deposition surface ofthe substrate 10, and the pitch and distance of the voids, i.e., spacebetween adjacent dielectric guiding features 25′, uniquely determine thedensity, position and orientation of the later deposited nanomaterials20.

As illustrated in FIG. 8A, in some embodiments, the sidewalk of theadjacent dielectric guiding features 25′ may be parallel to one another.In some embodiments, the distance D1 separating the sidewalks ofadjacent dielectric guiding features 25′ may range from 5 nm to 1000 nm.In another embodiment, the distance D1 separating the sidewalk ofadjacent dielectric guiding features 25′ may range from 5 nm to 1000 mm.In some embodiments, the distance separating the sidewalk of adjacentdielectric guiding features 25′ is selected to contain a singlenanostructure. In some embodiments, the pitch P1 separating openingsbetween adjacent dielectric guiding features 25′ may range from 10 nm to2000 nm. The term pitch P1 denotes the center to center distanceseparating adjacently positioned openings. In another embodiment, thepitch P1 separating openings between adjacent dielectric guidingfeatures 25′ may range from 10 nm to 2000 nm. In some embodiments, thepitch P1 is selected to provide the pitch separating adjacentlyorientated nanostructures, e.g., single nanostructures.

It is noted that the above example dimensions are provided forillustrative purposes only and not intended to limit the presentdisclosure. For example, FIG. 8C illustrates one embodiment in which thedistance separating adjacent sidewalls of the dielectric guidingfeatures 25′ and the pitch separating adjacently positioned openingsbetween the dielectric guiding features 25′ is greater than theembodiment depicted in FIG. 8A.

In the embodiments depicted in FIGS. 8A and 8C, the dielectric guidingfeatures 25′ have a length that is perpendicular to the length of theelectrically conductive material 20, i.e., electrodes 20. The presentdisclosure is not limited to only this example. For example, the lengthof the dielectric guiding features 25′ may be non-perpendicular to thelength of the electrically conductive material 20, i.e., electrodes 20,as depicted in FIG. 8D. For example, the sidewall of the dielectricguiding features 25′ may intersect with the sidewall of the electricallyconductive material 20 at an angle ranging from 5° to 95°. In otherexamples, the sidewall of the dielectric guiding features 25′ mayintersect with the sidewall of the electrically conductive material 20at an angle ranging from 15° to 85°. In yet other examples, the sidewallof the dielectric guiding features 25′ may intersect with the sidewallof the electrically conductive material 20 at an angle ranging from 30°to 60°.

FIG. 8B depicts a side cross-sectional view of the structure depicted inFIG. 8A. The upper surface of the dielectric guiding feature 25′ is notconformal. The upper surface of the dielectric guiding feature 25′ thatis depicted in FIG. 8B includes a raised portion that is overlying theelectrically conductive material 20, i.e., electrode. The upper surfaceof the dielectric guiding feature 25′ substantially conforms to theupper surface of the electrically conductive material 20, i.e.,electrodes, having a geometry similar to the dielectric material 4depicted in FIG. 1B. For example, the dielectric guiding feature 25′ hasa transition from the raised portion of the layer to the remainingportion of the layer that is recessed relative to the raced portion, inwhich the transition is proximate to the corner of the electricallyconductive material 20, and the transition has a curved sidewall. Thedielectric guiding feature 25′ having the topography depicted in 8B issimilar the topography of the dielectric layer 4 depicted in FIG. 1B;and therefore the dielectric guiding feature 25′ when subjected to anelectric field can produce an attractive force for orientatingnanostructures similar to the attractive forces that are described abovewith reference to FIGS. 1A-1C.

FIGS. 9A and 9B depict the orientation of nanostructures 30 on thedeposition surface of a substrate 10, wherein an electric field 35produced by the electrically conductive material 20, i.e., electrodes,transmitted through the dielectric guide features 25′ creates anattractive force that guides the nanostructures 30 to the depositionsurface. The term “nanostructure” denotes a material structure havingone dimension, e.g., a length or width, or diameter, of less than 1micron. One-dimensional nanostructures 30 are nanowires (nanorod) andnanotubular materials with fiber (rod, tube) lengths from 100 nm to tensof microns. Two-dimensional nanostructures 30, such as nanosheets, arefilms (coatings) with nanometer thickness. In some embodiments, thenanostructures 30 may be a carbon nanotube, e.g., single wall carbonnanotubes (CNT) or multi-wall carbon nanotubes (SWNT). “Nano tube” asused herein is meant to denote one form of nanostructure having anaspect ratio of length to width greater than 10. The term “nanotube”includes single wall and multi-wall nanotubes unless specificallyspecified as distinct. In one embodiment, a carbon nanotube is at leastone graphene layer wrapped into a cylinder. In one embodiment, a singlewall carbon nanotube is a graphene rolled up into a seamless cylinderwith diameter of the order of a nanometer. A multi-wall carbon nanotubeis a plurality of graphene sheets rolled up into a seamless cylinderwith diameter of the order of a nanometer. The diameter of the carbonnanotube that may be employed as the nanostructures 30 may be equal to 1nm or 2 nm or a value between 1 nm and 2 nm. The longest dimension ofthe carbon nanotube may range from about 0.5 nanometers to about 10microns. In another embodiment, the greatest dimension of a single wallnanotube ranges from about 100 nanometers to about 10 millimeters. Inone embodiment, the nanotubes used in accordance with the methods andstructures disclosed herein have an aspect ratio of length, i.e.,longest dimension, to width, i.e., diameter, on the order ofapproximately 1,000:1.

The nanostructures 30 may also be graphitic materials, such as carbonblack (CB), graphitic fibers, diamond like carbon (DLC) and graphiteplatelets. The nanostructures 30 may be dispersed in a liquid medium,such as an aqueous medium, or an alcohol based medium to facilitate asolution-assisted deposition process that is illustrated in FIG. 9B. Inother embodiments, the nanostructures 30 may be dispersed in toluene.

Still referring to FIGS. 9A and 9B, the solution of the nanostructures30 may be applied to the dielectric guiding features 25′ and thedeposition surface of the substrate 10. For example, the substrate 10may be submerged in the solution containing the nanostructures 30.Thereafter, an electric field 35 is produced by the electrodes, i.e.,electrically conductive material 20. In some embodiments, producing anelectric field 35 by the electrodes that is attenuated by the dielectricguide features 25′ to create an attractive force that guides thenanostructures 30 to the deposition surface.

More specifically, the nanostructures 30 are attracted by the electricfield that is generated between the metal electrodes 20 by applying anexternal voltage. The voltage can be alternative voltage (also referredto as “AC voltage”) or direct voltage (also referred to as “DCvoltage”), as desired. When an alternative voltage is employed, thecharacteristic frequency of the voltage is on a megahertz scale, e.g.,from about 0.1 MHz to about 10 MHz, or from about 0.5 MHz to about 1.5MHz, say, about 1 MHz. Other frequencies are not excluded from the scopeof the present invention. The voltage can be applied for a time periodof at least 1 minutes, more preferably from about 1 minutes to about 10minutes, but other time periods are not excluded from the scope of thepresent disclosure.

Referring to FIG. 9A, the top view schematics visualize how thenanostructures 30 are moved into the voids of the dielectric guidefeatures 25′. The pitch and distance of the voids in the dielectricguide features 25′ uniquely determine the density, position andorientation of the nanomaterials. In the embodiment that is depicted inFIG. 9A a single nanostructure 30 that may be provided by a carbonnanotube 30 is present in each void between adjacent dielectric guidefeatures 25′. Each nanostructure 30 may extend into contact with eachelectrically conductive material 20, e.g., electrode.

FIGS. 10A and 10B depict removing the dielectric over-layer (alsoreferred to as guides) features 25′ from the structure depicted in FIGS.9A and 9B. The process for removing the dielectric guide features 25′may remove the dielectric over-layer features selectively to thenanostructures 30 and the electrically conductive material 20. Thedielectric guide features 25′ may be removed by an etch process, such asa wet chemical etch, or a dry etch, e.g., reactive ion etch (RIE) orplasma etching.

It is to be appreciated that the use of any of the following “/”,“and/or”, and “at least one of”, for example, in the cases of “A/B”, “Aand/or B” and “at least one of A and B”, is intended to encompass theselection of the first listed option (A) only, or the selection of thesecond listed option (B) only, or the selection of both options (A andB). As a further example, in the cases of “A, B, and/or C” and “at leastof A, B, and C”, such phrasing is intended to encompass the selection ofthe first listed option (A) only, or the selection of the second listedoption (B) only, or the selection of the third listed option (C) only,or the selection of the first and the second listed options (A and B)only, or the selection of the first and third listed options (A and C)only, or the selection of the second and third listed options (B and C)only, or the selection of all three options (A and B and C). This may beextended, as readily apparent by one of ordinary skill in this andrelated arts, for as many items listed.

Having described preferred embodiments of a system and method (which areintended to be illustrative and not limiting), it is noted thatmodifications and variations can be made by persons skilled in the artin light of the above teachings. It is therefore to be understood thatchanges may be made in the particular embodiments disclosed which arewithin the scope of the invention as outlined by the appended claims.Having thus described aspects of the invention, with the details andparticularity required by the patent laws, what is claimed and desiredprotected by Letters Patent is set forth in the appended claims.

The invention claimed is:
 1. A method of positioning nanomaterials,comprising: patterning guiding dielectric features from a single layerof guiding dielectric material; and producing an electric field byelectrodes disposed on a substrate, the electric field being attenuatedthrough the guiding dielectric features to create an attractivedielectrophoretic force that guides at least one nanostructure abuttingthe guiding dielectric features to be positioned on a deposition surfaceof the substrate without being positioned directly atop the guidingdielectric features.
 2. The method of claim 1, further comprising:forming the electrodes on the substrate as a set of electrodes; andcovering the set of electrodes and substrate with the single layer ofguiding dielectric material.
 3. The method of claim 1, wherein thesingle layer of guiding dielectric material includes a material selectedfrom the group consisting of: silicon oxide, silicon nitride, hafniumoxide, aluminum oxide, and combinations thereof.
 4. The method of claim1, further comprising applying a liquid medium containing the at leastone nanostructure to the dielectric guide features and the depositionsurface.
 5. The method of claim 4, wherein the dielectric guide featuresinclude a dielectric material selected from the group consisting of:silicon oxide, silicon nitride, silicon oxynitride, aluminum oxide,hafnium oxide, and combinations thereof.
 6. The method of claim 1,wherein the at least one nanostructure includes a structure selectedfrom the group consisting of: carbon nanotube, nanowire, nanorod,nanosheet, carbon black (CB), graphitic fiber, diamond like carbon(DLC), and graphite platelet.
 7. A method of positioning nanomaterials,comprising: forming a set of electrodes on a substrate; covering the setof electrodes and substrate with a single layer of guiding dielectricmaterial; patterning the single layer of guiding dielectric material toform dielectric guide features; applying a liquid medium including atleast one nanostructure to the guiding dielectric features and thedeposition surface; and producing an electric field by the set ofelectrodes, the electric field being attenuated by the dielectric guidefeatures to create a dielectrophoretic attractive force that guides theat least one nanostructure to a deposition surface of the substratewithout positioning the at least one nanostructure directly atop thedielectric guide features.
 8. The method of claim 7, wherein forming theset of electrodes further includes: forming a first mask on a surface ofthe substrate having openings for the set of electrodes; blanketdepositing an electrically conductive layer on the first mask, whereinthe electrically conductive layer fills the openings; and lifting thefirst mask.
 9. The method of claim 7, wherein covering the set ofelectrodes and the substrate with the single layer of guiding dielectricmaterial further includes using chemical vapor deposition.
 10. Themethod of claim 7, wherein patterning the guiding dielectric materialfurther includes performing photolithography and etch processes.
 11. Themethod of claim 10, wherein the etch process includes an anisotropicetch process.
 12. The method of claim 7, wherein the dielectric guidefeatures are composed of a dielectric material selected from the groupconsisting of: silicon oxide, silicon nitride, silicon oxynitride,aluminum oxide, hafnium oxide and combinations thereof.
 13. The methodof claim 7, wherein the at least one nanostructure includes a structureselected from the group consisting of: carbon nanotube, nanowire,nanorod, nanosheet, carbon black (CB), graphitic fiber, diamond likecarbon (DLC), and graphite platelet.
 14. A method of positioningnanomaterials, comprising: covering a substrate and a set of electrodesformed on the substrate with a single layer of guiding dielectricmaterial; patterning the single layer of guiding dielectric material toform dielectric guide features; and producing an electric field by theset of electrodes, the electric field being attenuated by the dielectricguide features to create an attractive force that guides at least onenanostructure to a deposition surface of the substrate withoutpositioning the at least one nanostructure directly atop the dielectricguide features.
 15. The method of claim 14, further comprising formingthe set of electrodes on the substrate, including: forming a first maskon a surface of the substrate having openings for the set of electrodes;blanket depositing an electrically conductive layer on the first mask,wherein the electrically conductive layer fills the openings; andlifting the first mask.
 16. The method of claim 15, wherein covering thesubstrate and the set of with the single layer of guiding dielectricmaterial further includes using chemical vapor deposition.
 17. Themethod of claim 14, wherein patterning the guiding dielectric materialfurther includes performing photolithography and etch processes.
 18. Themethod of claim 14, wherein the dielectric guide features include adielectric material selected from the group consisting of: siliconoxide, silicon nitride, silicon oxynitride, aluminum oxide, hafniumoxide and combinations thereof.
 19. The method of claim 14, wherein theat least one nanostructure includes a structure selected from the groupconsisting of: carbon nanotube, nanowire, nanorod, nanosheet, carbonblack (CB), graphitic fiber, diamond like carbon (DLC), and graphiteplatelet.
 20. The method of claim 14, wherein the at least onenanostructure is a single nanotube between each pair of dielectric guidefeatures.